Just (4 days ago) replaced the head gasket and studs/bolts on my son's 97 2.2OHV. Horrible job, by the way - but the car was fine until today when it wouldn't start (again). Before the gasket replacement he had coolant spraying out from 2 studs - guess they'd stretched - and the gasket was, indeed, blown. Cylinders were full of coolant too. Thorough inspection of head and block revealed no other damage though. I was going to replace the thermostat today but when he tried to start the car to go to Autozone for a new one we discovered coolant leaking - under pressure as the engine turned - from the exhaust pipe to exhaust manifold joint! He'd only driven the car 4 times for around 15 miles total and lost 2 or 3 pints from the header tank over the previous 4 days.

Anyone have any ideas what the problem might be?

T4

 

i would have had the head checked for straightness and pressure tested before i put it back on .

 

x2 ^^^^

 

But surely (I know, don't call you Shirley) that wouldn't result in a coolant leak at the exhaust pipe to manifold joint, would it? No sign anywhere else of coolant leak.
T4

 

It would have to be leaking into the exhaust inside the engine.

 

So, a warp or a crack then. Seems a bit terminal!